EP0097494A2 - Appareil pour le revêtement - Google Patents

Appareil pour le revêtement Download PDF

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Publication number
EP0097494A2
EP0097494A2 EP83303496A EP83303496A EP0097494A2 EP 0097494 A2 EP0097494 A2 EP 0097494A2 EP 83303496 A EP83303496 A EP 83303496A EP 83303496 A EP83303496 A EP 83303496A EP 0097494 A2 EP0097494 A2 EP 0097494A2
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EP
European Patent Office
Prior art keywords
gas
support
gas jetting
jetting device
coating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP83303496A
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German (de)
English (en)
Other versions
EP0097494B1 (fr
EP0097494A3 (en
Inventor
Takeshi Kishido
Tetsuya Yoshino
Takashi Kageyama
Kazuo Kato
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Konica Minolta Inc
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Konica Minolta Inc
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Publication date
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Publication of EP0097494A2 publication Critical patent/EP0097494A2/fr
Publication of EP0097494A3 publication Critical patent/EP0097494A3/en
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Publication of EP0097494B1 publication Critical patent/EP0097494B1/fr
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C9/00—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important
    • B05C9/06—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important for applying two different liquids or other fluent materials, or the same liquid or other fluent material twice, to the same side of the work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C5/00—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work
    • B05C5/007—Slide-hopper coaters, i.e. apparatus in which the liquid or other fluent material flows freely on an inclined surface before contacting the work
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03C—PHOTOSENSITIVE MATERIALS FOR PHOTOGRAPHIC PURPOSES; PHOTOGRAPHIC PROCESSES, e.g. CINE, X-RAY, COLOUR, STEREO-PHOTOGRAPHIC PROCESSES; AUXILIARY PROCESSES IN PHOTOGRAPHY
    • G03C1/00—Photosensitive materials
    • G03C1/74—Applying photosensitive compositions to the base; Drying processes therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C9/00—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important
    • B05C9/04—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important for applying liquid or other fluent material to opposite sides of the work
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03C—PHOTOSENSITIVE MATERIALS FOR PHOTOGRAPHIC PURPOSES; PHOTOGRAPHIC PROCESSES, e.g. CINE, X-RAY, COLOUR, STEREO-PHOTOGRAPHIC PROCESSES; AUXILIARY PROCESSES IN PHOTOGRAPHY
    • G03C1/00—Photosensitive materials
    • G03C1/74—Applying photosensitive compositions to the base; Drying processes therefor
    • G03C2001/7425—Coating on both sides

Definitions

  • the present invention relates to a coating apparatus for applying a liquid to the surfaces of a flexible support sheet (referred to simply as "support”, hereinunder) while carrying the support without contacting the same. More particularly, the invention is concerned with a coating apparatus for coating one or two kinds of liquid on a support such as a photosensitive photographic material while carrying the support at its surface opposite to the coated surface and allowing the same to run continuously. Still more particularly, the invention is concerned with a coating apparatus suited to continuous coating of both sides of the support.
  • the support is subjected twice to the same steps, ie. the application of the liquid, gelation of the liquid and drying, such that the application of the liquid to the second side is started after the drying of the coating film on the first side.
  • various methods have been proposed to form coating layers on both sides of the support by making the latter to pass the steps of application and drying only once, in order to attain a higher productivity. These methods are grouped into several types in one of which the application of the liquid to the second side is made after gelation of the coating film on the first side.
  • a severe management of the coating system is required to eliminate scratching or dust in or on the roll surface because the coating is failed even by a slight scratch or dust in or on the supporting roll surface.
  • the coating layer is disturbed when a portion of the support having a fluctuation of the coating film thickness, e.g. the portion where the application is started, spliced portions and so forth passes the supporting roll in contact with the latter.
  • a part of the gelated liquid may attach to the supporting roll surface to disturb the coating layer on the following portion of the support.
  • the method disclosed in Japanese Patent Publication No. 17853/1974 involves a problem that, since the variation of the lift in the widthwise direction becomes large as the width of the support gets large, it is difficult to press the end of the coater uniformly to the support and, hence, to obtain a uniform thickness of the coating layer on the entire surface of the support.
  • the coating film thickness is apt to be varied because no specific consideration is given to the prevention of the vibration of the support at the front and rear sides of the coater.
  • the distance between the support surface and the end of the coater at both marginal ends of the support where the latter is carried by the supporting roll is not equal to that at the other portions of the support out of contact with the supporting roll.
  • the difference of the aforementioned distance becomes larger as the width of the support becomes greater. In the worst case, some portions of the support may not be coated by the liquid at all.
  • the position of the support at portions thereof other than both marginal ends carried by the supporting roll is determined by a delicate balance between the back pressure (T/R, T: tensile strength, R: radius of curvature of support surface) produced by the tension and the reduced pressure applied by the coater.
  • T/R back pressure
  • R radius of curvature of support surface
  • the end of the coater and the outer surface of the gas jetting device are constructed as linearly as possible along the width direction of the support. Therefore, the coater gap will be uniformalized along the width direction of the support within the tolerance of the machining, provided that the lift of the support from the surface of the gas jetting device is uniform along the width direction of the support.
  • the lift of the support is fluctuated largely along the width direction of the support because no positive measure has been taken for uniformalizing the lift. Therefore, it has been quite difficult to obtain a practical application device which can uniformly apply the liquid.
  • the uniform lift of the support along the width direction becomes more difficult as the width of the support gets larger, and this problem becomes more serious as the width of the support is increased beyond about 500 mm.
  • the support width usually exceeds 500 mm in most coating apparatus designed for attaining a high productivity, it is almost impossible to avert from the above-described problem in developing a non-contact carrying type coating apparatus for coating both sides of the support.
  • the term "wide support” is used to mean support having a width exceeding 500 mm, while the term “narrow support” means support of width less than 500 mm.
  • an object of the invention is to provide a coating apparatus for coating both sides of a support, wherein the support is carried without being contacted mechanically but by the jet of a gas from a gas jetting device while eliminating any fluctuation of the floating distance so that the liquid is applied to the side of the support opposite to the gas jetting device without any unevenness of thickness in the form of transverse stripes while avoiding any unevenness of thickness due to blowing on the first coated side upon which the gas jet impinges, so that coating layers of uniform thickness are formed on both sides of the support thereby to overcome the above-described problems of the prior art.
  • a coating apparatus having a coater and a gas jetting device disposed to oppose to each other across a continuously running support, in that the coating is made by the coater while the support is carried in a non-contacting manner by a gas jetted from the gas jetting device towards the support, and the gas jetting device has a hollow housing into which the gas is introduced from a source, the wall of the housing adjacent to the support being provided with a plurality of gas jetting nozzle ports through which the gas is jetted towards the support, each gas jetting nozzle port having a throat portion presenting a minimum cross-sectional area inwardly spaced from the outer surface of the wall of the housing and an enlarged outlet portion presenting a comparatively large diameter and opening in the surface of the wall, the minimum diameter presented by the throat portion ranging between 0.02 and 0.5 mm and the maximum diameter presented by the enlarged outlet portion ranging between 0.5 and 5 mm.
  • the throat portion and the enlarged outlet portion are formed by boring a through hole of the same diameter as the enlarged outlet portion in the wall of the gas jetting device, and embedding and fixing a pierce tube in the through hole, the pierce tube having a configuration to substantially close the through hole and having an inside diameter substantially equal to that of the throat portion.
  • the present inventors have made various studies on the coating methods and apparatus of non-contact carrying type such as those listed in i) and ii) before, and have reached the following conclusion.
  • the essence of the non-contact type carrying technic is to form, between the support and the outer surface of the gas jetting device, a space of a static pressure higher than the ambient pressure, i.e. the pressure on the side of the support to which coating is made by the coater, by jetting the gas from the gas jetting device so as to keep the support afloat above the gas jetting device, thereby to carry the support by the high static pressure without permitting the support to contact the surface of the gas jetting device.
  • non-contact carrying region The region where the high static pressure for carrying the support is established will be referred to as "non-contact carrying region" hereinunder.
  • the non-contact carrying method in the apparatus of the invention is based upon substantially the same principle.
  • T/R tension applied to the support
  • R radius of curvature of curved portion
  • the support is moved to and held a position where the back pressure and the carrying static pressure balance each other. More specifically, the space of the high static pressure is continuously supplied with the gas jetted from the gas jetting device. The outgoing flow of the gas from this space, however, is made to pass a restricted gap between the support and the gas jetting device and, accordingly, encounters a resistance determined by the size of the gap, i.e. the lift of the support, so that the high static pressure determined by the factors including the rate of incoming flow of gas and the above-mentioned flow resistance is established and maintained in the above-mentioned space.
  • the rate of reduction of the back pressure is much smaller than the rate of reduction of the carrying static pressure to cause an apparent increase of the back pressure to urge the support towards the gas jetting device.
  • the lift is decreased followed by an increase in the flow resistance, so that the support is settled at a lift where the carrying static pressure balancing the back pressure is maintained, i.e. at the same lift as that obtained before the increase of the lift.
  • This process for the determination of the lift is performed equally also when the back pressure is changed first. Namely, the lift is changed to attain the balance between the back pressure and the carrying static pressure and always takes the value corresponding to the rate of jetting of the gas.
  • the unevenness of the coating layer thickness in the form of transverse step lines experienced in the coating method and apparatus mentioned in ii) before is attributable to the fluctuation of the lift as stated above. It proved that the amplitude of the fluctuation of the lift is as large as several tens of microns. This phenomenon will be explained in more detail.
  • the fundamental cause of the lift fluctuation is a fluctuation in the tension applied to the support, which in turn causes not only a change in the ratio T/R, i.e. the back pressure but also a fluctuation in the rate of jetting of the gas, resulting in an amplified fluctuation of the lift.
  • the gas In the jetting of the gas, the gas is driven by the force proportional to the difference between the source pressure and the carrying static pressure.
  • the carrying static pressure is changed also to balance the back pressure. Assuming that the back pressure is, for instance, increased, the lift is decreased while the carrying static pressure is increased. In consequence, if the gas source pressure is constant, the rate of jetting of the gas is decreased because the differential pressure is reduced, so that the decrease in the lift is amplified. In other words, if the rate of jetting of the gas is maintained constant, the fluctuation in the lift is minimized even if the tension in the support is changed by disturbance. In this case, the generation of unevenness in the form of transverse step lines is avoided advantageously.
  • the best way to meet all requirements is to construct the gas jetting ports in such a manner as to permit the dispersion of the gas jetted at a constant rate from the jetting device over an area as wide as possible.
  • the present inventors have accomplished the coating apparatus of the invention on the basis of these knowledges and finding out. Namely, the present inventors have succeeded in developing a coating apparatus which is freed from the problems such as unevenness of thickness in the form of transverse step lines as well as the unevenness of thickness due to blowing on the side of the support upon which the jetted gas impinges, by arranging such that, while the gas is jetted at a constant rate from the surface of the gas jetting device, the stream line of the gas jetted from each gas jetting port drastically diverges to impinge upon the coated surface of the support over an area as wide as possible.
  • Another object of the invention is to provide a coating apparatus for forming coating layer or layers of highly uniform thickness on a web-like flexible support such as a photosensitive photographic material, wherein the application of the coating liquid to the support is made while carrying the support in non-contacting manner and maintaining a constant coater gap along the width direction of the support.
  • Still another object of the invention is to provide a coating apparatus for coating both sides of a support, wherein the support is required to pass through a drying section only once to permit a high production efficiency of the coating process in an industrial scale.
  • the invention provides a coating apparatus as mentioned before further comprising means for adjusting the ratio of port area in such a manner that the rate of jetting of the gas from unit area of the outer surface of the gas jetting device becomes smaller as the width of the support is increased.
  • the ratio of port area in the gas jetting device for carrying wide support is adjusted to meet the condition of W 2.
  • the term of ratio of port area in this case is not a local value but is a mean value over the entire part of the non-contact carrying region.
  • the non-contact carrying region is the region except the boundary 13 between the area in which the support is affected by the gas jetted from the jetting device and the area in which the support is not affected by the gas, as well as the widthwise marginal end portions where the ratio of port area is greater than in other areas.
  • the boundary 13 the gas jetted from the jetting device is directly relieved to the outside to decrease the lift of the support.
  • the boundary 13, therefore, is independent from the means for adjusting the ratio of port area in accordance with the support width for jetting the gas at a large rate to prevent the contact of the support.
  • the support 2 is coated with a liquid by a known process employing a coater 1 while being carried by a supporting roll 3 in direct contact with the latter.
  • the support 2 is then made to pass through a cold air zone 8 in which cold air is applied to the coating layer 4 through a slitted plate or a group of apertures 7.
  • the support 2 having the coating layer 4 on its one side is made to pass through the non-contact carrying region of a gas jetting device 3' of the coating apparatus of the invention, where the liquid is applied by a coater 1' onto the opposite side of the support 2 to the coating layer 4 to form a coating layer 11.
  • a gas jetting device 3' of the coating apparatus of the invention, where the liquid is applied by a coater 1' onto the opposite side of the support 2 to the coating layer 4 to form a coating layer 11.
  • the illustrated embodiment employs, by way of example, a hollow roll type device which is considered as being most popular from the view point of strength and easiness of fabrication.
  • a gas is jetted through a plurality of gas jetting nozzle ports 10 formed in the surface 9 of the gas jetting device against the support surface carrying the coating layer 4 so as to suspend and carry the support without allowing the latter to be carried by a direct contact with solid part of the apparatus.
  • it is strictly required to maintain the fluctuation of the thickness of the coating layer in the wet or dried state within 1%.
  • the width or amplitude of fluctuation of the gap size is preferably within several microns and should not exceed 10 microns at the greatest.
  • the gas jetted from the gas jetting nozzle ports 10, directly impinging upon the gelated layer 4, may cause an unevenness due to blowing.
  • each nozzle port 10 of the gas jetting device 3' has a throat portion l0a where the diameter of the port takes the minimum diameter d l of 0.02 to 0.5 mm and an enlarged outlet portion lOb of a diameter d 2 of 0.5 to 5 mm.
  • the fluctuation of the lift of the support 2 in the non-contact carrying region is attributable to a fluctuation of the tension in the support, caused by a vibration or oscillation of the support.
  • vibration or oscillation of the support 2 takes place in the direction perpendicular to the running direction thereof, because the support 2 after leaving the gas jetting device 3' carries undried layers on both sides thereof and, hence, cannot be supported by direct contact.
  • the fluctuation in the tension is caused also by a fluctuation in the driving power exerted by the driving source itself.
  • the variation in the tension in the support 2 directly causes a variation in the back pressure and, hence, a variation in the lift.
  • the lift i.e. the distance between the surface of the coating layer 4 and the surface 9 of the gas jetting device at a portion of the non-contact carrying region near the end of the coater 1' was measured while varying the tension applied to the support 2, the result of which is shown in Fig. 4. More specifically, curves A, B and C appearing in Fig. 4 were obtained with different gas jetting devices A, B and C all of which are of the hollow roll type.
  • the gas jetting device A has a construction as shown in Fig. 2 in section.
  • each gas jetting nozzle 10 has a constant diameter d of 2 mm over its entire length lwhich is 5 mm.
  • the ratio of the port area which will be defined as follows, is selected to be 1%.
  • the term "ratio of port area” in this specification is used to mean the ratio of the sum of cross-sectional areas of throat portions of all nozzle ports in the plane perpendicular to the gas jetting direction to the whole area of the outer surface of the gas jetting device.
  • the gauge pressure of the gas at which the latter is introduced and supplied to the hollow 12 of the gas jetting device is 0.03 Kg/cm 2 . This pressure will be referred to as "supply pressure", hereinunder.
  • the gas jetting device B has a construction similar to that of the device A. In this device, however, the diameter d and the length of the jetting nozzle port 10 is 0.1 mm and 10 mm, respectively, while the ratio of port area is 0.1%.
  • the coating was conducted at a gas supply pressure of 1 Kg/cm 2 , while other factors are not changed from those in the experiment conducted with the jetting device A.
  • the fluctuation of the lift is suppressed to about 10 microns at the greatest, even if there is any fluctuation in the tension, so that the generation of unevenness of thickness in the form of transverse step lines is generally avoided.
  • the thickness unevenness in the form of transverse step lines may be formed in the coating layer 11 if the fluctuation in the gas supply pressure or the tension in the support exceeds the normal value.
  • the gas jetting device C is the one which is incorporated in the coating apparatus of the invention. As will be seen from Fig.
  • each nozzle port 10 in this gas jetting device has a stepped wall, i.e. two portions of different diameters. Namely, each nozzle port 10 has a throat portion 10a of an inside diameter d l of 0.1 mm and a length l 1 of 10 mm, and an enlarged outlet portion 10b having an inside diameter d 2 of 2 mm and a length l 2 of 3 mm.
  • Other conditions are same as those in the experiment conducted with the gas jetting device B. It was confirmed that, with this gas jetting device, the fluctuation of the lift of the support 2 can be suppressed to about 8 microns and the thickness unevenness in the form of transverse step lines is completely eliminated.
  • the gas jetting device in order to restrain the fluctuation of the lift of the support 2, it is necessary that the line tangent to the curve in the graph shown in Fig. 4 approaches the horizontal line within the normal range of the tension.
  • the gas jetting devices B and C were designed taking this point into account. Namely, these gas jetting devices are so constructed that a pressure sufficiently higher than the static pressure in the non-contact carrying region is maintained within the gas jetting device, so that only a negligibly small change is caused in the pressure differential between the inside of the gas jetting device and the non-contact carrying region even when there is a change in the carrying static pressure, i.e.
  • the driving force for jetting the gas is determined by the above-mentioned differential pressure
  • the rate of the jetting of the gas is substantially unchanged because the change in the differential pressure is negligibly small.
  • the internal gas pressure of the gas jetting device is maintained sufficiently high as compared with the static pressure in the non-contact carrying region for the following reason. Namely, the minimum cross-sectional area, i.e. the cross-sectional area of the throat portion of each nozzle port 10 through which the interior 12 of the gas jetting device is communicated with the non-contact carrying region is extremely small to impose a considerable resistance to the flow of the gas therethrough.
  • the carrying static pressure is not perfectly uniform over the entire area but has a certain distribution in accordance with the pattern of the flow of the gas. Namely, the static pressure is highest in the areas confronting the outlets of the nozzle ports 10 and the static pressure is drastically decreased as the distance from the outlets is increased.
  • the jetting nozzle port 10 is made to have an enlarged outlet portion of an increased diameter, intended to enlarge or widen the area in which the maximum static pressure is established.
  • the change in the back pressure caused by a change in the tension is less liable to be transmitted to the outlet portion of the gas jetting port 10. Therefore, the fluctuation in the gas jetting rate is further decreased even in comparison with the gas jetting device B and the fluctuation of the float is diminished correspondingly.
  • the absolute value of the lift is the absolute value of the lift. Namely, if the lift is too small, there is a fear that the coating layer 4 undesirably contacts the outer surface 9 of the gas jetting device at the splice portion or other portion having large thickness. In such a case, a part of the coating layer may attach to the surface 9 of the gas jetting device to contaminate and disorder the trailing portion of the coating layer 4.
  • the gas jetting device B is not free from this problem.
  • the gas jetting device C the mutual contact between the coating layer 4 and the surface 9 of the gas jetting device is avoided because the effective static carrying pressure is increased to maintain a sufficiently large lift of the support.
  • the gas jetting device C is effective also in the elimination of the unevenness of thickness due to blowing. Namely, experiments were conducted with gas jetting devices A, B and C for coating both sides of the support by a method as illustrated in Fig. 1.
  • the undesirable thickness unevenness due to blowing was inevitably found in the coating layer formed with the gas jetting device A.
  • the unevenness of thickness was also found in the coating layer formed with the gas jetting device B, by a too high gas supply pressure, insufficient gelation of the layer in the cold air zone 8 and other reasons.
  • the unevenness of thickness due to blowing was not found at all in the coating layer formed with the gas jetting device C.
  • gas colliding area This area will be referred to as "gas colliding area", hereinunder.
  • the gas jetted from the gas jetting nozzle port 10 is made to collide with the coating layer 4, while diverging or spreading its flow path partly because there is no means for restricting the flow of the gas after emerging from the nozzle port and partly because the pressure around the nozzle port is sufficiently low.
  • the momentum brought by the gas per unit area of the gas colliding area gets smaller as the density of the gas is decreased due to divergence of the flow of gas.
  • the divergence of the flow of gas is affected by the following three factors independently.
  • collision distance the distance between the outlet of the gas jetting port 10 and the surface of the coating layer 4 (referred to as “collision distance”, hereinunder) and the linear velocity of the gas jetted from the gas jetting device.
  • the momentum of the gas in each case will be discussed hereinunder taking these factors into account, for clarifying the difference in the mechanism of generation of the unevenness of thickness due to blowing.
  • the diameter d of the gas jetting nozzle port 10 is about 10 times as large as the gas collision distance, i.e. the lift of the support.
  • the divergence of the flow path of gas is comparatively small, so that the most part of the gas comes into collision with the gas colliding area which is substantially equal to the cross-sectional area of the outlet of the gas jetting nozzle 10, without being decelerated substantially. In consequence, a large momentum is imparted to this gas colliding area to cause an unevenness of thickness due to blowing.
  • the diameter d of the gas jetting nozzle port is about 1/20 of that in the device A, and is substantially in a 1 : 1 relation to the collision distance.
  • the flow path of the jetted gas diverges comparatively largely to make the gas collide with the gas colliding area which is considerably greater than the cross-sectional area of the outlet portion of the gas jetting nozzle 10.
  • the effect of divergence of the flow path is dominant because the linear velocity of the gas is substantially equal to that produced by the gas jetting device A, since the number of the gas jetting nozzle ports is geater while the total rate of jetting of the gas is smaller. In consequence, the generation of thickness unevenness due to blowing is suppressed considerably as compared with the case of the gas jetting device A.
  • the nozzle port 10 in the gas jetting device C has the enlarged outlet portion 10b which offers the following advantage. Namely, in the nozzle port 10 in .
  • the divergence of the flow path of the gas is materially started at the outlet side of the throat portion 10a.
  • the collision distance is not equal to the lift of the support but is the sum of the lift and the length l 2 of the enlarged outlet portion lOb. In this case, therefore, the collision distance is more than 30 times as large as the diameter of the gas jetting nozzle port 10 which is in this case the diameter d l of the thorat portion 10a.
  • the divergence of the flow path of the gas is much greater than that in the gas jetting device B. Considering that other factors such as linear velocity of the gas are identical to the case of the gas jetting device B, it is clear that the gas jetting device C is more effective in eliminating the undesirable unevenness of thickness due to blowing.
  • the gas jetting device has a hollow casing in the wall of which formed are the gas jetting nozzle ports for jetting out the gas supplied to the hollow of the device. It is necessary that each gas jetting nozzle port has a throat portion of an extremely small cross-sectional area for imposing a large pressure drop of the gas to be jetted, followed by a portion of a drastically increased diameter, i.e. the enlarged outlet portion.
  • the diameters of the throat portion and the enlarged outlet portion optimumly range between 0.02 and 0.5 mm and between 0.5 and 5 mm, respectively.
  • the diameter of the gas jetting nozzle port in this specification, is the diameter of an imaginary circle having an area equal to the cross-sectional area of the nozzle port taken at a plane perpendicular to the direction of flow of the gas. Namely, it is not essential that the cross-section of the port is actually circular.
  • the determination of the relation between the diameter of the throat portion and the diameter of the enlarged outlet portion is made first with the determination of the diameter of the throat portion. As stated before, the smaller the diameter of the throat portion becomes, the more the fluctuation of the lift of support is suppressed. The smaller diameter of the throat portion, however, reduces the rate of jetting of the gas undesirably.
  • the lengths of the throat portion and the enlarged outlet portion are also the factors which rule the effect of the gas jetting nozzle port having the throat portion and enlarged outlet portion.
  • the lengths of these portions of the nozzle port are preferably long.
  • it is not necessary to preserve large lengths for these portions of the nozzle port because, although the pressure drop is affected by the length of the nozzle port, the same is affected by the square of the diameter.
  • the throat portion need not have large length for the same reason.
  • the length of the throat portion therefore, is determined in accordance with factors such as easiness of machining.
  • the preferred range is laid also on the length of the enlarged outlet portion as stated above. More specifically, for the diameters specified before, the lengths of the throat portion and the enlarged outlet portion preferably range between 5 and 30 mm and between 1 and 5 mm, respectively. These ranges of the lengths, however, are not exclusive and respective portions of the gas jetting nozzle port can have lengths falling out of these preferred ranges.
  • the gas supply pressure at which the gas is supplied to the gas jetting device 3' is preferably 0.1 to 5 Kg/cm 2 .
  • a gas supply pressure less than 0.1 Kg/cm 2 will not be able to develop necessary pressure difference between the interior of the gas jetting device 3' and the non-contact carrying region, whereas a gas supply pressure in excess of 5 Kg/cm 2 requires an extremely small diameter of the throat portion lOa of the gas jetting nozzle port 10.
  • This range of the gas supply pressure is only a preferred one and the invention can fairly be carried out with gas supply pressure falling out of the range specified above, as will be easily understood by those skilled in the art.
  • any gas having no possibility to cause danger e.g. N 2 gas, freon gas and air can be used as the gas supplied to the gas jetting device, although the air can be most conveniently used.
  • N 2 gas, freon gas and air can be used as the gas supplied to the gas jetting device, although the air can be most conveniently used.
  • freon gas and air can be used as the gas supplied to the gas jetting device, although the air can be most conveniently used.
  • the air it is necessary to clean the air by means of an air cleaner before it is supplied to the gas jetting device, for otherwise troubles such as clogging of the nozzle ports may be caused.
  • any material can be used as the material for the gas jetting device 3', if it is strong enough to withstand the internal gas pressure.
  • preferred materials are stainless steel and brass steel plated with hard chromium.
  • the use of plastic is also preferred from the view point of easiness of formation of the gas jetting nozzle ports 10.
  • Material for supporting photosensitive material such as plastic films, e.g. polyethylene terephthalate, triacetyl cellulose and so forth, as well as paper, can be used as the flexible support used in the invention.
  • the present invention offers the following advantages.
  • FIG. 1 A preferred embodiment of the invention has been described with reference to Figs. 1 to 4.
  • the invention is not limited to the described embodiment, and the essence of the invention is to use a gas jetting device which has a continuous curved outer surface cooperating with the support in defining therebetween a gap in which a static carrying pressure is established, the gas jetting device having gas jetting nozzle ports each having the throat portion of restricted cross-sectional area and an enlarged outlet portion.
  • the roll-like form of the gas jetting device in the illustrated embodiment is not exclusive, and the invention can employ gas jetting devices having different constructions.
  • the gas jetting device can have the form of a semi-circular cylinder or an oval cylinder or, as'shown in Fig.
  • the application of the liquid to one and the other sides of the support can be conducted by known methods such as bead application method, extrusion application method and liquid film method.
  • each fluid jetting nozzle port in the gas jetting device has an extremely small diameter and a considerable length. It is quite difficult to form such a nozzle port by a mechanical processing. Namely, the smaller the diameter of the bore is, the more difficult the drilling becomes. The drilling is materially impossible when the depth of the bore gets large. Therefore, the gas jetting device is fabricated by, for example, a process as shown in Fig. 5. According to this process, nozzle ports 10 having an inside diameter equal to the diameter of the enlarged outlet portion 10b are formed in the wall of the hollow casing.
  • pierce tubes 13 having a small through bore of a diameter equal to the diameter of the throat portion 10a is fitted in and fixed to the wall of each nozzle port 10, to complete the gas jetting device.
  • the diameter of the enlarged outlet portion 10b is large enough to permit the formation by drilling. It is even possible to select the diameter of the enlarged outlet portion lOb at such a value as to permit an easy formation by drilling.
  • the pierce tube 13, which has an outside diameter equal to the inside diameter of the enlarged outlet portion lOb and provided with a small through hole of a diameter equal to that of the throat portion lOa can be formed by using, for example, ceramics as the material.
  • Another advantage brought about by this process is that the length of the enlarged outlet portion lOb and the length of the throat portion 10a can be determined simultaneously. Namely, since the length of the pierce tube made of a ceramics can be selected freely while the fixing of the tube can be made easily by an adhesive 14 of, for example, epoxy group, it is also possible to select the length of the enlarged outlet portion lOb freely. In addition, undesirable leak of the gas through the gap around the pierce tube 13 can be avoided by fixing the pierce tube 13 by the adhesive 14 applied to the outer peripheral surface of the latter as shown in the drawings.
  • a coating apparatus as shown in Fig. 1 was constructed to have a gas jetting device 3' in the form of a hollow roll which is provided in its wall with a plurality of gas jetting nozzle ports 10 each having two portions of different diameters as shown in Fig. 3.
  • the radius of the outer surface of the roll was selected to be 100 mm.
  • Each gas jetting nozzle port 10 had a throat portion 10a and an enlarged outlet portion lOb both having circular cross-sections.
  • the diameter d l and the length l 1 of the throat portion were selected to be 0.08 mm and 10 mm, respectively, while the diameter d 2 and length l 2 of the enlarged outlet portion 10b were determined to be 1.5 mm and 3 mm, respectively.
  • the ratio of port area was 0.02%.
  • Clean air filtrated by a filter of 2 microns mesh was supplied into the hollow 12 of the gas jetting device 3' at a gauge pressure of 1 Kg/cm 2 and was jetted from the gas jetting nozzle ports 10.
  • the support 2 used was a film of polyethylene terephthalate of 0.18 mm thick having a width of 400 mm, which was fed at a speed of 20 m per minute under a tension of 0.1 Kg/cm width. Then, emulsion of silver halide sensitive to Rontgen ray, together with gelatine as a binder, was applied by means of a coater (slide hopper ) 1 to form an underlying layer onto which further applied was an aqueous solution of gelatine as a protective layer.
  • the thicknesses of the underlying layer and the protective layer immediately after the application were 55 microns and 20 microns, respectively. Then, in the cold air zone 8, cold air chilled to about 5°C was applied through the slitted plate 7 to the coating layer 4 to gelate the latter. After the gelation of the layer 4, double-layer coating was effected on the other side of the support by a coater (slide hopper) 1' operating under the same condition as the coater 1, while the support is carried in the non-contact manner in the non-contact carrying region. The support was then forwarded to the drying after gelation of the coating layer 11. The coating layer 11 thus formed had a uniform thickness and was entirely free from coating defect such as unevenness of thickness in the form of transverse step lines. The coating layer 4 also was finished in a good manner without suffering from disorder of the coating layer surface due to contact with the surface 9 of the gas jetting device and unevenness of thickness due to blowing.
  • Coating on both sides of a support was conducted under the same condition as Example 1, although the feeding speed was increased to 100 m per minute. Coating layers having uniform thicknesses and suffering no coating defect were formed on both sides of the support as in the case of Example 1.
  • a coating apparatus was constructed in which the contact type supporting roll 3 was substituted by a gas jetting device having the same construction as the device 3' so that the support was carried in a non-contacting manner also in the region where the application is made by the coater 1. Coating was effected on both sides of the support with this coating apparatus. After the drying, coating layers of uniform thicknesses and having no coating defect were formed.
  • the roll type gas jetting device 3' had a plurality of gas jetting nozzle ports 10 each having a throat portion 10a and an enlarged outlet portion lOb.
  • the diameter d l and the length l 1 of the throat portion were 0.2 mm and 15 mm, respectively, while the diameter d 2 and length l 2 of the enlarged outlet portion 10b were 3 mm and 5 mm, respectively.
  • the ratio of port area was selected to be 0.1%. Clean air filtrated by an air filter of 2 microns mesh was supplied into the hollow 12 of the gas jetting device at a gauge pressure of 0.2 Kg/cm 2 and was jetted from the gas jetting nozzle ports 10.
  • a polyethylene terephthalate film of 0.1 mm thick having a width of 400 mm was used as the support.
  • the support 2 was fed at a speed of 40 m per minute under a tension of 0.1 Kg/cm width. Then, a coating was conducted on one side of the support 2 by the coater 1 to form an underlying layer of aqueous solution of gelatine dissolving an antihalation color element for photography and a protective layer of aqueous solution of gelatine.
  • the thicknesses of the underlying layer and the protective layer were 50 microns and 20 microns, respectively, in the state immediately after the application.
  • the coating layer 4 consisting of two layers was cooled and gelated by cold air of about 5°C applied through the slitted plate 7 in the cold air zone 8. Then, while carrying the support in a non-contacting manner, a coating was effected on the other side of the support 2 under the same condition as above to form an underlying layer of emulsion of silver halide as a photosensitive material for printing together with gelatine as a binder and an overlying layer of aqueous solution of gelatine as the protective layer. These layers formed on the other side of the support had thicknesses of 60 microns and 20 microns in the state immediately after the drying. After the gelation of the coating layer 11 constituted by these two layers, the support was subjected to a drying step. The coating layer 11 had uniform thickness and exhibited no unevenness of thickness in the form of transverse step lines. The coating layer 4 also was finished in good order without suffering from any damage due to contact with the outer surface 9 of the gas jetting device and unevenness of thickness due to blowing.
  • a construction which permits an easy change of the ratio of port area For instance, it is possible to use an arrangement shown in Fig. 9 in which two or more gas jetting devices each having the gas jetting nozzle ports are lapped for sliding motion relatively to each other. In use, these gas jetting devices are slided to meet the width of the support to be coated as indicated by an arrow in this Figure to adjust the degree of lap of the gas jetting nozzle ports, thereby to vary the minimum cross-sectional area in each passage of the gas.
  • the gas jetting device is provided at its widthwise end portions with annular peripheral ridges 15 so as to oppose to both marginal edges of the support 2 but not to contact the latter, as will be seen from Figs. 7 and 8. According to this arrangement, it is possible to impose a resistance on the flow of gas which tends to escape laterally from both marginal edges of the support. It is also possible to provide, in order to prevent any decrease of the lift of support at both widthwise end portions of the latter, means for increasing the rate of jetting of air only at regions opposing to both widthwise end portions of the support. This can be achieved by arranging such that the ratio of port area is greater at both axial end portions of the gas jetting device than that in the central region of the same.
  • a coating apparatus having the construction as illustrated in Fig. 1 was used for effecting coating on a support having a width of 1,000 mm.
  • a hollow roll type gas jetting device 3' having a plurality of gas jetting nozzle ports 10 as shown in Fig. 3 was employed.
  • the radius of the roll surface was selected to be 100 mm.
  • Each gas jetting nozzle port had a throat portion and an enlarged outlet portion both having circular cross-sections.
  • the diameter d l and the length l 1 of the throat portion were selected to be 0.05 mm and 10 mm, respectively, while the diameter d 2 and length l 2 of the enlarged outlet portion were determined to be 1.5 mm and 3 mm, respectively.
  • the ratio of port area was selected to be 0.002%.
  • the diameter d and the lengths were selected to be 180 microns and 10 mm, respectively, and the ratio of port opening was determined to be 0.157%, over the entire width of the support.
  • Air was supplied to the hollow of the roll type gas jetting device at a gauge pressure of 1.0 Kg/cm 2 and was jetted through the gas jetting nozzle ports 10.
  • the mean value of the gas jetting rate per unit area of the non-contact carrying region was 6.33 N ml/min ⁇ cm 2 .
  • the value W 2 .Q is calculated to be 6.33 x 1 0 4 .
  • the length L of the non-contact type carrying region is substantially equal to R ⁇ , where 6 represents the angle over which the support is affected by the roll type gas jetting device.
  • This angle will be referred to as "lap angle", hereinunder.
  • the angle 0 is 180° so that the length L is about 157 mm. Since the support 2 is carried in a non-contacting manner, the gas jetting device 3' is not rotated. It is, of course, possible to rotate the gas jetting devide having gas jetting nozzle ports over the entire periphery thereof, but such an arrangement is not essential.
  • a solution as the material of photosensitive photographic layer was applied by a coater 1 such as a slide hopper to one side of the support 2 while the latter was carried by an ordinary direct contact type back-up roll 3 to form a coating layer 4 which was gelated as the support 2 passed through the cold air zone 8. Then, while the support 2 was supported in a non-contacting manner by the gas jetting device 3', a solution as the photosensitive material was applied by a coater 1' such as a slide hopper onto the opposite side of the support 2 to the coating layer 4 to become a coating layer 11. In this case, a solution for Rontgen photography was used.
  • each coater 1, 1' was conducted to form a double layer consisting of an underlying layer of emulsion of silver halide sensitive to Rontgen ray together with gelatine as a binder, and an overlying protective layer consisting of aqueous solution of gelatine, such that the underlying and overlying layers have thicknesses of 55 microns and 20 microns, respectively, in the wet state.
  • the support 2 was a polyethylene terephthalate film of 180 microns and was fed at a speed of 50 m per minute under the tension of 0.1 Kg/cm width. The lift of the support 2, i.e.
  • the distance between the outer surface of the gas jetting device and the coating layer 4 was 200 microns at the central portion opposing to the end of the coater 1' and 170 microns at both widthwise end portions.
  • the values of lift in other portions all fall within the region between 200 microns and 170 microns.
  • Example 5 Another experiment was conducted under the same condition as Example 5 except that the number of the gas jetting ports were increased to increase the ratio of port opening to 0.02%.
  • the amount of lift in this case was 380 microns at the central portion of the support opposing to the coater 1' and 200 microns at both widthwise end portions.
  • the value W 2 .Q therefore was calculated to be 6.33 x 10 5 . It was found that, even though the coater gap is optimumly adjusted at the central portion of the support, the coater gaps at both widthwise end portions undesirably get greater and the solution cannot be applied by the coater 1' to both widthwise end portions of the support. Namely, it was not possible to effect uniform coating.
  • Coating was effected on both sides of a support under the same condition as Example 5 excepting that the support was fed at an elevated speed of120 m per minute. After a drying, uniform coating layers having no unevenness such as longitudinal stripes was obtained on both sides of the support 2 as in the case of the
  • the path of the support upstream from the gas jetting device 3' was changed to allow the lap angle of the gas jetting device 3' to be increased to 250°.
  • the number of the gas jetting ports was increased corresponding to the increment of the lap angle.
  • Other conditions were materially indentical to those of Example 5.
  • the amounts of lift were 230 microns at the central portion and 200 microns at both widthwise end portions of the support.
  • the amount of lift at other portions of the support all falled within this region.
  • uniform coating layers were formed on both sides of the support without suffering from any coating defect.
  • Coating was conducted under the same condition as Example 5, excepting that the radius R was changed to 50 mm.
  • the amounts of lift were 170 microns at the central portion and 150 microns at both widthwise end portions of the support, respectively. Uniform coating layers having no defect were formed as in the case of Example 5.
  • Example 8 Coating was conducted on both sides of the support under the same condition as Example 8 except that the support feed speed was increased to 120 m per minute. After a drying, a uniform coating layers having no defect such as longitudinal stripes were obtained on both sides of the support as in the case of Example 8.
  • Coating was conducted under the same condition as Example 7 except that the radius R was changed to 50 mm.
  • the amounts of lift were 200 microns at the central portion and 180 microns at both widthwise end portions of the support. Uniform coating layers having no defect was obtained as in the case of
  • the coating apparatus as shown in Fig.l was used to effect coating on both sides of a polyethylene terephthalate film of 100 microns thick and 2000 mm wide with a solution of photosensitive material for printing.
  • a roll type gas jetting device having a radius R of 100 mm was used.
  • annular peripheral ridges 15 having a height h of 300 microns, width w of 10 mm and a length L of 300 mm were formed on the outer surface of the roll type gas jetting device so as to oppose to both marginal ends of the support.
  • the gas jetting portions were constituted by circular gas jetting ports having a diameter d of 50 microns and length 2 of 10 mm.
  • the number of the gas jetting ports wasdecreased to reduce the ratio of port area down to 0.0008%.
  • the gas was supplied at a pressure of 1.0 Kg/cm 2 to obtain a gas jetting rate Q of 2.5 N ml/min cm 2 .
  • the value W 2 .Q was calculated to be 10 5 .
  • two layers were formed on first side of the support by the coater 1: namely, an underlying layer of aqueous solution of gelatine dissolving a color element and an overlying protective layer of aqueous solution of gelatine at thicknesses of 55 microns and 20 microns, respectively, in the wet state.
  • a coating was effected by the coater 1' on the other side of the support to form an underlying layer of emulsion of silver halide as a photosensitive material for printing and an overlying protective layer of aqueous solution of gelatine at thicknesses of 55 microns and 20 microns, respectively, in the wet state.
  • the support was then subjected to a non-contact type carrying and non-contact type drying.
  • the amounts of lift of the support was maximum (400 microns) at the central portion opposing to the end of the coater 1' and minimum (370 microns) at both widthwise end portions of the support.
  • uniform coating layers having no coating defect were formed on both sides of the support.
  • the photosensitive film thus produced exhibited superior photographic performance.
  • Coating was conducted under the same condition as Example 10 excepting that the diameter of the gas jetting nozzle ports was increased to 180 microns to realize a greater ratio of port area of 0.05%, in both widthwise end regions of a width w' of 10 mm (see Fig. 8). In consequence, the lift was maintained within 10 microns over the whole width of the portion of the support opposing to the end of the coater 1'. With this arrangement, uniform coating layers having no unevenness such as longitudinal stripes were formed by a coating operation conducted under the same condition as Example 11, even at an elevated support feed speed of 120 mm per minute.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Coating Apparatus (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
EP83303496A 1982-06-22 1983-06-16 Appareil pour le revêtement Expired EP0097494B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP57106136A JPS58223457A (ja) 1982-06-22 1982-06-22 塗布装置
JP106136/82 1982-06-22

Publications (3)

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EP0097494A2 true EP0097494A2 (fr) 1984-01-04
EP0097494A3 EP0097494A3 (en) 1984-08-22
EP0097494B1 EP0097494B1 (fr) 1988-01-07

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EP83303496A Expired EP0097494B1 (fr) 1982-06-22 1983-06-16 Appareil pour le revêtement

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US (1) US4561378A (fr)
EP (1) EP0097494B1 (fr)
JP (1) JPS58223457A (fr)
DE (1) DE3375226D1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0366481A2 (fr) * 1988-10-28 1990-05-02 Konica Corporation Appareil de revêtement de tissu

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3589331A (en) * 1969-04-04 1971-06-29 Westinghouse Electric Corp Apparatus for coating metallic foil
DE2164121A1 (de) * 1970-12-29 1972-07-13 Fuji Photo Film Co. Ltd., Ashigara-Kamigun, Kanagawa (Japan) Verfahren und Vorrichtung zum Abstützen und Trocknen von Bandmaterial mittels Luftkissen
DE2812351A1 (de) * 1977-03-22 1978-09-28 Fuji Photo Film Co Ltd Verfahren zum beidseitigen oberflaechenbeschichten einer bahn
US4241111A (en) * 1977-08-11 1980-12-23 Fuji Photo Film Co., Ltd. Process for consecutively coating both sides of web
WO1983001585A1 (fr) * 1981-11-04 1983-05-11 Yoshino, Tetsuya Procede et dispositif de revetement des deux cotes d'un substrat

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4178397A (en) * 1978-07-12 1979-12-11 Bethlehem Steel Corporation Method and apparatus for treating one side of a strip

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3589331A (en) * 1969-04-04 1971-06-29 Westinghouse Electric Corp Apparatus for coating metallic foil
DE2164121A1 (de) * 1970-12-29 1972-07-13 Fuji Photo Film Co. Ltd., Ashigara-Kamigun, Kanagawa (Japan) Verfahren und Vorrichtung zum Abstützen und Trocknen von Bandmaterial mittels Luftkissen
DE2812351A1 (de) * 1977-03-22 1978-09-28 Fuji Photo Film Co Ltd Verfahren zum beidseitigen oberflaechenbeschichten einer bahn
US4241111A (en) * 1977-08-11 1980-12-23 Fuji Photo Film Co., Ltd. Process for consecutively coating both sides of web
WO1983001585A1 (fr) * 1981-11-04 1983-05-11 Yoshino, Tetsuya Procede et dispositif de revetement des deux cotes d'un substrat
EP0093177A1 (fr) * 1981-11-04 1983-11-09 Konica Corporation Procede et dispositif de revetement des deux cotes d'un substrat

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0366481A2 (fr) * 1988-10-28 1990-05-02 Konica Corporation Appareil de revêtement de tissu
EP0366481A3 (fr) * 1988-10-28 1991-11-21 Konica Corporation Appareil de revêtement de tissu
US5136966A (en) * 1988-10-28 1992-08-11 Konica Corporation Web coating apparatus

Also Published As

Publication number Publication date
DE3375226D1 (en) 1988-02-11
JPS58223457A (ja) 1983-12-26
EP0097494B1 (fr) 1988-01-07
US4561378A (en) 1985-12-31
EP0097494A3 (en) 1984-08-22
JPH048113B2 (fr) 1992-02-14

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